MacDon MD #147595 B M155 Installation guide

Brand: MacDon

Model: MD #147595 B M155

Type: Installation guide

The harvesting specialists.

M155

Self-Propelled Windrower

Oil Cooler Bypass Kit (MD #183518) Installation Instructions

147595 Revision B

Original Instruction

Published: January 2016

Introduction

The Oil Cooler Bypass kit (MD #183518) is used to replace the cooler bypass manifold and the hardware on the

wheel motor servo on an M155 Self-Propelled Windrower. This document explains how to install the kit.

Refer to the parts list to ensure you have all required items before installing this kit.

Installation Time

Installation time for this kit is approximately six hours.

Conventions

The following conventions are followed in this document:

• Right-hand (RH) and left-hand (LH)aredetermined from theoperator’sposition, facing forward with the windrower

in cab-forward position.

• Unless otherwise noted, use the standard torque values provided in the windrower operator’s manual and

technical manual.

NOTE:

Keep your MacDon publications up-to-date. The most current version of this instruction can be downloaded from

our Dealer-only site (https://portal.macdon.com) (login required).

NOTE:

This document is not currently available in any language except English.

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Revision B

List of Revisions

At MacDon, we’re continuously making improvements, and occasionally these improvements affect product

documentation. The following list provides an account of major changes from the previous version of this document.

Summary of Change Location

Created topic. 3.1.5 Testing Cooler Bypass Pressure, page 12

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TABLE OF CONTENTS

Introduction...................................................................................................................................... i

List of Revisions ...............................................................................................................................ii

1 Safety.................................................................................................................................................... 1

1.1 Signal Words................................................................................................................................... 1

1.2 General Safety................................................................................................................................ 2

2 Parts List............................................................................................................................................... 5

3 Installation Instructions ........................................................................................................................ 9

3.1 Cooler Bypass Manifold ................................................................................................................... 9

3.1.1 Preparing Kit Components for Installation .................................................................................. 9

3.1.2 Changing the Hydraulic Oil ....................................................................................................... 9

3.1.3 Replacing Cooler Bypass Manifold.......................................................................................... 10

3.1.4 Reﬁlling Hydraulic Reservoir................................................................................................... 12

3.1.5 Testing Cooler Bypass Pressure.............................................................................................. 12

3.2 Wheel Drive Motor Servo Hardware (2014 and Prior Only)............................................................... 14

3.2.1 Removing Drive Wheel........................................................................................................... 14

3.2.2 Replacing Servo Hardware.....................................................................................................15

3.2.3 Reinstalling Drive Wheel......................................................................................................... 19

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1Safety

1.1 Signal Words

Three signal words, DA NG E R, WARNING, and CAUTION, are used to alert you to hazardous situations. The

appropriate signal word for each situation has been selected using the following guidelines:

DANGER

Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It

may also be used to alert against unsafe practices.

CAUTION

Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It

may be used to alert against unsafe practices.

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SAFETY

1.2 General Safety

CAUTION

The following are general farm safety precautions

that should be part of your operating procedure for

all types of machinery.

Protect yourself.

• When assembling, operating, and servicing machinery,

wear all the protective clothing and personal safety

devices that could be necessary for the job at hand.

Don’t take chances. You may need the following:

• Hard hat

• Protective footwear with slip resistant soles

• Protective glasses or goggles

• Heavy gloves

• Wet weather gear

• Respirator or ﬁlter mask

Figure 1.1: Safety Equipment

• Be aware that exposure to loud noises can cause

hearing impairment or loss. Wear suitable hearing

protection devices such as ear muffs or ear plugs to

help protect against objectionable or loud noises.

Figure 1.2: Safety Equipment

• Provideaﬁrstaidkitforuseincaseofemergencies.

• Keep a ﬁre extinguisher on the machine. Be sure the

ﬁre extinguisher is properly maintained. Be familiar with

its proper use.

• Keep young children away from the machinery at

all times.

• Be aware that accidents often happen when the

Operator is tired or in a hurry. Take the time to

consider the safest way. Never ignore the warning

signs of fatigue.

Figure 1.3: Safety Equipment

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SAFETY

• Wear close-ﬁtting clothing and cover long hair. Never

wear dangling items such as scarves or bracelets.

• Keep all shields in place. Never alter or remove safety

equipment. Make sure driveline guards can rotate

independently of the shaft and can telescope freely.

• Use only service and repair parts made or approved by

the equipment manufacturer. Substituted parts may not

meet strength, design, or safety requirements.

Figure 1.4: Safety around Equipment

• Keep hands, feet, clothing, and hair away from moving

parts. Never attempt to clear obstructions or objects

from a machine while the engine is running.

•DoNOT modify the machine. Non-authorized

modiﬁcations may impair machine function and/or

safety. It may also shorten the machine’s life.

• To avoid bodily injury or death from unexpected startup

of machine, always stop the engine and remove the

key from ignition before leaving operator’s seat for

any reason.

Figure 1.5: Safety around Equipment

• Keep the service area clean and dry. Wet or oily ﬂoors

are slippery. Wet spots can be dangerous when working

with electrical equipment. Be sure all electrical outlets

and tools are properly grounded.

• Keep work area well lit.

• Keep machinery clean. Straw and chaff on a hot

engine is a ﬁre hazard. Do NOT allow oil or grease to

accumulate on service platforms, ladders, or controls.

Clean machines before storage.

• Never use gasoline, naphtha, or any volatile material

for cleaning purposes. These materials may be toxic

and/or ﬂammable.

• When storing machinery, cover sharp or extending

components to prevent injury from accidental contact.

Figure 1.6: Safety around Equipment

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2PartsList

The following parts are included in this kit.

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PARTS LIST

Figure 2.1: Parts Included in Oil Cooler Bypass Kit (MD #183518)

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PARTS LIST

Ref

Part

Number Description Quantity

1 183494 MANIFOLD – COOLER BYPASS 1

2 21031 FITTING – ADAPTER HYDRAULIC 1

3 183493 HOSE 1

4 134437 FITTING – COUPLING HYDRAULIC TEST PORT 2

5 50086 FITTING – HYDRAULIC TEE 1

A 136652 SCREW – HEX SOC HD M6 X 1.00 X 20-12.9-A2L 16

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3 Installation Instructions

To install the Oil Cooler Bypass kit (MD #183518), follow these procedures in order.

IMPORTANT:

Do NOT attempt to install the Oil Cooler Bypass kit in the ﬁeld. The hydraulic hose and ﬁttings must be kept clean

during installation to avoid hydraulic system damage.

IMPORTANT:

Protect the ends of hoses, ﬁttings, and ports from contamination with clean, lint-free towels or clean plastic bags.

3.1 Cooler Bypass Manifold

3.1.1 Preparing Kit Components for Installation

To prepare the cooler bypass manifold components for installation, follow these steps:

1. As shown in the illustration at right, attach the two test

port ﬁttings (MD #134437) (A) to ports CRG and CPG

on the new cooler bypass manifold (MD #183494) (B).

All parts are provided in the kit.

2. Attach the adapter ﬁtting (MD #21031) (C) provided in

the kit to port DR on the manifold.

Figure 3.1: New Cooler Bypass Manifold with

Fittings

3.1.2 Changing the Hydraulic Oil

DANGER

To avoid bodily injury ordeath from unexpected startup of the machine, always stop the engine and remove

the key from the ignition before leaving the operator’s seat for any reason.

To drain hydraulic oil, follow these steps:

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INSTALLATION INSTRUCTIONS

1. Park the windrower on level ground, and lower the

header and reel so that the lift cylinders are fully

retracted.

2. Stop the engine and remove the key.

3. Open the hood.

For instructions, refer to the windrower operator’s

manual or technical manual.

4. Place a clean container (at least 20 US gallons

[75 liters]) under drain at the bottom of the hydraulic

reservoir to collect the oil.

5. Remove drain plug (A) and allow oil to drain.

6. Inspect particles and clean off any metal debris that

may have accumulated on magnetic plug. Wipe plug

with a clean cloth. Check O-ring condition. Look for

cracking, breakage, or deformation that may impede

sealing ability and replace as required.

7. Install drain plug (A), torque to 59 ft·lbf (80 N·m).

Figure 3.2: Hydraulic Oil Drain Plug

3.1.3 Replacing Cooler Bypass Manifold

To replace the cooler bypass manifold, follow these steps:

1. At the bottom of the hydraulic reservoir, detach

hose (A) from elbow ﬁtting (B).

2. Removeelbow ﬁtting (B) and replace with hydraulictee

ﬁtting (MD #50086) from the kit. Discard elbow ﬁtting.

Figure 3.3: Bottom LH End of Hydraulic

Reservoir

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INSTALLATION INSTRUCTIONS

3. Reattach hose (A) from the reel and conveyor pump to

the middle of the new tee ﬁtting (B).

4. Attach hose (MD #183493) (C), provided in kit, to the

open end of tee ﬁtting (B).

Figure 3.4: Bottom LH End of Hydraulic

Reservoir

5. On the left side of the windrower, inside the frame,

attach a cable tie (not provided in kit) to hose (A) or

mark the hose to ensure that you remember where to

reattach it later.

6. Disconnect hoses and lines (A) and (D) attached to the

existing cooler bypass manifold (B).

7. Disconnect the existing cooler bypass manifold (B)

from the ﬁlter (C) next to it.

8. One at atime, transferﬁttingsfrom the oldmanifold(B)

to the new manifold (MD #183494) provided in the kit.

Fittings should be positioned as shown in Figure 3.6:

Hydraulic Ports on New Cooler Bypass Manifold, page

11. Discard the old manifold.

9. Install the new manifold in place of the old. Port F on

the new manifold connects to the ﬁlter head.

Figure 3.5: Inside LH Frame (View from Below)

10. Connect the hoses and lines disconnected in Step 6.,

page 11 to the new manifold as follows:

• Port CR – the cooler return hose

• Port CP – the hose from the oil cooler marked in

Step 5., page 11

• Port A – the steel line from Port T2 on the

multifunction control block

• PortB– the5/8in. hosefrom the inboard gearpump

• Port P2 – the 1/4 in. hose from the lift manifold block

11. Attach the new hose from Step 4., page 11 to the

adapter ﬁtting in Port DR of the new manifold.

Figure 3.6: Hydraulic Ports on New Cooler

Bypass Manifold

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INSTALLATION INSTRUCTIONS

3.1.4 Reﬁlling Hydraulic Reservoir

To reﬁll the hydraulic reservoir, follow these steps:

1. Stand on left-hand platform to access the ﬁller pipe.

2. Turn ﬁller cap (A) counterclockwise to unlock cap and

remove dipstick.

Figure 3.7: Windrower Hood

3. Add oil to maintain a level between the LOW and FULL

marks, and make sure that no debris falls into the

reservoir.

• Oil type: SAE 15W-40 compliant with SAE specs

for API Class SJ and CH-R engine oil

• Reservoir capacity: 17.2 U.S. gallons (66 liters)

4. Reinstall dipstick and ﬁller cap, and turn clockwise to

tighten/lock.

5. Close thehood. Forinstructions, refer tothe windrower

operator’s manual or technical manual.

Figure 3.8: Hydraulic Oil Level

3.1.5 Testing Cooler Bypass Pressure

IMPORTANT:

Make sure you check CP and CR pressure after installing the new Oil Bypass Cooler kit, and adjust as necessary.

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INSTALLATION INSTRUCTIONS

1. To measure CR pressure, attach a 1000 psi (7000 kPa)

pressure gauge to the test ﬁtting at port CRG (A).

2. To measure CP pressure, do one of the following:

• Attach a 1000 psi (7000 kPa) pressure gauge to the

test ﬁtting at port CPG (B); OR

• Attach a ﬂow meter capable of reading ﬂow as high

as 28 gpm (106 lpm) and a 1000 psi (7000 kPa)

pressure gauge between port CP and cooler. The

test equipment must attach to the #12 JIC ﬁtting at

port CP on the cooler bypass manifold.

3. Start engine and run at high idle (wide open throttle)

until hydraulic oil temperature is between 135–145°F

(57–63°C). If using a ﬂow meter, the reading should be

between 20–24 gpm (76–91 lpm).

4. Record CP and CR pressures. CP pressure should be

between 500–605 psi (3447–4171 kPa).

5. If CP pressure is not between 500–605 psi

(3447–4171 kPa), adjust pressure by removingcap(C)

and increasing or decreasing cooler bypass setting by

turning adjustment screw.

NOTE:

CR pressure is not adjustable.

6. When CP pressure is in the correct range, subtract the

CR pressure reading from the CP pressure reading.

The differential pressure should range between

80–200 psi (552–1380 kPa). A differential pressure

lower than 80 psi (552 kPa) indicates a possible

defective hydraulic cooler.

Figure 3.9: Hydraulic Ports on New Cooler

Bypass Manifold

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INSTALLATION INSTRUCTIONS

3.2 Wheel Drive Motor Servo Hardware (2014 and Prior Only)

Along with the parts required to replace the cooler bypass manifold, the kit also includes 16 hex socket head

screws. These are needed to replace the hardware on both wheel drive motor servos on windrowers from model

years 2014 and earlier. Follow the remaining procedures twice: once for the right-hand wheel drive and once for

the left-hand wheel drive.

NOTE:

These procedures are NOT required for 2015 windrowers. The motors on these windrowers already have

the required hardware.

3.2.1 Removing Drive Wheel

To remove the drive wheel, follow these steps:

CAUTION

To avoid bodily injury or death from unexpected

startup of machine, always stop engine and remove

key from ignition before leaving operator’s seat for

any reason.

1. Place ground speed lever (GSL) in N-DETENT (A),

shut down engine, and remove key.

Figure 3.10: Ground Speed Lever

CAUTION

Jack stand must be capable of supporting a minimum

of5000lb.(2268kg).

2. Place a jack under the leg jack point (A), and raise the

drive wheel until it is slightly off ground. Place a jack

stand beneath the lift cylinder mount (B).

NOTE:

Do NOT place jack stand under the cylinder. Use a

small metal plate on top of the jack stand.

3. Lower the windrower onto the jack stand.

Figure 3.11: Drive Wheel Jack Point

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MacDon MD #147595 B M155 Installation guide

Brand: MacDon

Model: MD #147595 B M155

Type: Installation guide

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MacDon MD #147595 B M155 Installation guide

MacDon MD #147595 B M155 Installation guide

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